ECS/CemScanner

PP-7004.CEM.0001
Experience from 600
+
installations worldwide is refected in the reliability,
quality and performance of the ECS/CemScanner The state-of-the-art
in kiln shell infrared scanning systems
ECS/CemScanner

ECS/CemScanner

The operator user-interface of different sections contains informative presentations of the kiln shell heat conditions:
OThe thermal profle, O Lining (bricking profle), O Thermal Image, O Cross-section plot (polar or X-Y), O Live Ring
Migration (LRM), O Zoom Image (3D or 2D), O { X-Y coordinates and temperature of cursor position, O Combined 3D thermal and 3D
coating thickness view, O Detailed and real-time monitoring of ring formations in the kiln. Depending on the users needs, a number of
user-interface setups can be selected from the toolbar.
The thermal image represents the entire fattened shell surface,
with up to 65K user-defned colour codes giving an indication of
the temperature scale. The thermal profle consists of 4 super-
imposed curves showing the minimum, maximum, average and
worst case temperatures measured around the shell. It may also
display the alarm levels assigned to several kiln sections.
The 3D-IR view shows the thermal image of the kiln shell
animated in exact synchronisation with the kiln rotation speed.
This view enables the experience of a human look at the kiln with
infrared eyes! The walk-in-the-kiln view enables advanced
monitoring of the coating conditions for plant operators. In the
above screen shots, blockages in two satellite cooler knees are
clearly revealed.
Shell heat loss
Shell heat loss from the whole kiln and/or subsections is
calculated and can be displayed as trend curves.
Increased kiln availability
Lower refractory consumption
Fewer stops
Reduced thermal consumption
Ability to plan overhauls

Application
Correct measurement of the temperature on a kiln shell is essen-
tial for effcient operation of the kiln. ECS/CemScanner repre-
sents the state-of-the-art in kiln shell infrared scanning. It com-
bines a robust design with advanced software features, making
it an indispensable aid to the operation and optimisation of kilns.
The use of ECS/CemScanner will result in:
Diagnostic
Dedicated features providing comprehensive diagnostic informa-
tion on the equipment conditions, scanner raw data, and data
communication status are available for monitoring the system
and to facilitate maintenance.
Trend object
In addition to the built-in historical data, any specifc process data
such as shell temperatures in the burning zone and other sections
of the kiln, or maintenance data such as the scanner rotation
frequency can be logged for supervision, trend and early warning
purposes.
Refractory control
Usually, plant personnel in charge of refractory maintenance gain
valuable experience and know-how on the performance and life-
time of the refractory in the plant. Unless this information is
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General Description
RefraControl for brick lining management Brick and coating thickness calculation
centralised and systematically recorded, new planning of refrac-
tory lining becomes in-effcient because of insuffcient informa-
tion on refractory track record. At the same time, changing per-
sonnel at the plant can often mean loss of relevant experience.
Correct use and installation of refractories not only reduces re-
fractory costs, but also results in signifcant increase of kiln
availability and productivity. The optional package, RefraControl,
is a unique tool for management of all the relevant information
on refractory track-record, consumption, past installations and
future lining planning.
The software package includes graphical presentation of the his-
toric installations, lining arrangement, consumption and per-
formance reports for each installed brick type in the kiln. Addi-
tionally, a number of relevant data infuencing the refractory
lifetime such as raw mix chemistry, the quantity of clinker
produced, shell repairs, and kiln-stop reasons can be registered.
The integrated information base is thus a valuable tool for de-
tailed evaluation of refractory performance.
RefraControl system combines brick history with a stock control
system, a calculation and design module, bricking reports,
production reports, drilling history, availability analysis reports
and many other features.
Brick thickness
ECS/CemScanner is able to calculate brick and coating thickness
(not possible directly under the tyres and girth gear).The results
are displayed as profle or 3-dimensional image updated in real
time or based on historical data. Allowance is made for different
conductivities of the bricks, internal temperatures and conditions
causing abnormally high shell temperatures, not necessarily as a
result of thin bricks.
The calculation of brick and coating thicknesses is not an esti-
mate, but is based on solid theoretical grounds. Skilled users at-
tain accuracy results better than 10% i.e. within a few millime-
tres. To make sure that historical thickness calculations can be
compared, the system requires the use of an encoder to ensure a
precise kiln position indication.
Tyre slip
To ensure lining durability and to avoid kiln deformation or lining
damages during kiln startup and normal operation, the kiln oval-
ity must be kept within certain limits. The kiln shell ovality is
greatly affected by the degree of clearance between the tyres and
the kiln shell. The simplest and most accurate procedure is to
measure the kiln shell rotation in relation to the tyres rotation.
The derived result is termed tyre slip or live ring migration.
The optional Live Ring Migration (LRM) system is an automatic
and continuous online computer based measurement and regis-
tration system designed to monitor the tyre slip and to anticipate
and predict kiln constriction. It monitors the tyre slip by con-
stantly measuring the relative positions of the kiln and tyres or
the rotation time of the kiln and tyres. The slips are computed
with the help of statistical calculations to obtain reliable values.
The tyre slip for each tyre is indicated by a bar chart. They can also
be displayed as trend curves, ie. together with the shell tempera-
tures on both sides of the tyre. Slip alarm levels are indicated on
the bar chart and alarms for slip trend can also be generated.
L
Easy animation of all historical thermal profles, images,
snap-shots and worst case data
Along with the 2D view of the thickness conditions, the 3D walk-
in-the-kiln with selectable view-position (L) enables a practical
impression of the coating conditions, without stopping the kiln.
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FLSmidth A/S Automation. All rights reserved.
ECS/ProcessExpert, ECS/CEMulator, ECS/PlantGuide, QCX/RoboLab, QCX/OnStream, ECS/CemScanner,
ECS/ACESYS, ECS/ControlCenter, ACE/Woodware, ECS/SmartStation, ECS/StackGuide, QCX/Laboratory,
QCX/AutoSampling, QCX/AutoPrep, QCX/BlendExpert, QCX/BlendMaster and Kilnloq are either registered
trademarks or trademarks of FLSmidth A/S Automation in the United States and /or other countries. All other
trademarks are property of their respective owners.
FLSmidth Automation reserves the right to change specifcations without prior notice. Our brochure makes no
offers, representations or warranties (express or implied), and information and data contained in this brochure
are for general reference only and may change at any time. Please contact us for specifc information or data that
may relate to your interests.
The design of the scanning equipment enable it for withstand the harshest environments to provide
for long-term performance and trouble-free operation. The standard high-speed infrared scanner
used in the ECS/CemScanner is selected among the leading scanner suppliers offering high reliability,
and long-term stability and accuracy (see the separate data sheet on the supported scanner heads).
The scanner is enclosed in a cabinet and equipped with an atmospheric flter.
The protective stainless-steel scanner cabinet offers ample space for easy and open access to components. It is air-pressurised to maintain
a temperature below 50C, to avoid dust entry, and maintain a dust-free viewing window. An electro-magnetic shutter automatically
closes the window in case of power failure. The air is provided by an integrated high-power flter fan, which avoids the use of costly instru-
ment air. The cabinet is also equipped with temperature and pressure sensors which can be monitored via the software diagnostic
facilities.
The Scanner Front Interface module is based on CemMicro II technology which offers preci-
sion, speed, and data reliability. With a resolution of 14 bit, the unit handles typically more
than 1.2 million measurements for each kiln rotation. With this unit, a typical
ECS/CemScanner installation provides a temperature resolution of a half a brick.
Product Features
L Thermal profle with various statistical values
L Kiln cross-sectional view
L Zoom 2D or 3D
L 3D-IR kiln thermal view from adjustable view
angles
L 3D walk-in-the-kilnfor on-line coating supervision
L Replay of historical data in animated view
L Delta mode (comparison of two image profles)
L Calculated brick and/or coating thickness
L User-defne colour palette
L Confgurable on-line supervision of scanner hardware
conditions
L Optional OPC and PLC communication drivers for data
exchange with plant PLC and SCADA system
L User-interface supporting most major languages
L Support for Windows 2000/2003/XP platforms
Fan control
When using cooling fans to control the burning zone section,
ECS/CemScanner can optionally be equipped with automatic
control of the fans e.g. through the plant PLC system. Fans are
started when and where it is required by continuous temperature
supervision of the kiln sections. This option enables an optimized
use of the fans to prevent uneconomical continuous operation of
the fans thereby increasing their life time.
Pyrometers
If obstacles prevent the scanner from viewing parts of the kiln
shell, up to 8 infrared pyrometers can be installed to measure
temperatures in these specifc areas. With the PyroScan option,
temperatures of a particular section are scanned and integrated
into the thermal image and profle displays of the
ECS/CemScanner.
Integrated kiln camera
Spyrometer or kiln TV can optionally be displayed as an integral
part of an ECS/CemScanner system.
Stereo scanner
If it is not possible to obtain a clear view of the kiln shell with one
scanner head because of obstacles, one or more additional scan-
ner heads can be installed. The stereo scanner ensures that every
portion of the kiln shell is at least covered by one of the scanner
heads. The software functions react as if there were one scanner
head only. Furthermore the software can handle scanners for
several kilns.
ECS/CemScanner

Technical Data